Water heater inlet fitting, flow sensor, shut off valve and diffuser

ABSTRACT

An integrated valve and flow sensor for a water heater can have a valve body that includes a valve and a flow sensor for measuring the flow of water through the valve. The integrated valve and flow sensor can be disposed within a fitting that can be attached to a water heater. An actuator for opening and closing the valve can be attached to the fitting. A diffuser can also be attached to the fitting.

RELATED APPLICATIONS

The present application is a divisional application of U.S. patentapplication Ser. No. 16/042,386 filed Jul. 23, 2018, which claimspriority to U.S. Provisional Patent Application No. 62/535,592, filedJul. 21, 2017, the entire contents of which are incorporated herein byreference.

TECHNICAL FIELD

The present disclosure relates generally to water heaters andparticularly to water heater inlet fittings.

BACKGROUND

Boilers, water heaters, and other similar devices have various types ofwater inlet fittings. For example, gas water heaters typically have aninlet with a diffuser that extends into the water heater. The diffusercan be designed and positioned within the water heater to optimize thethermal efficiency of the water heater. The proper orientation andgeometry of the diffuser will deliver cold inlet water to the properlocation within the water heater allowing mixing and counter-flow andpreventing the cold inlet water from being directed at one or more heatexchanger pipes which could cause thermal stress. In one example, theoptimum orientation for the diffuser is the 2 o'clock position for thediffuser outlet, assuming the diffuser is positioned extendingvertically downward into the cylindrically shaped water heater tank, thediffuser outlet is on a side of the diffuser pointing outward toward awall of the water heater tank, the 12 o'clock position is pointinginward toward a gas flue running through the central longitudinal axisof the cylindrically shaped water heater tank, and the 6 o'clockposition is pointing outward directly towards the closest section of theouter wall of the water heater tank. Because the diffuser is a separatecomponent that must be attached to the gas water heater duringinstallation, there is an increased likelihood the installer may notposition the diffuser properly during the installation therebynegatively affecting the thermal efficiency of the water heater. Forexample, if the diffuser is attached to the water heater and then theseparate flow sensor is attached to the diffuser, torque is separatelyapplied to both the diffuser and the flow sensor. When torque is appliedto the flow sensor, there is a tendency for the diffuser to shift fromthe optimal position.

Another drawback in some existing water heaters is the length of thediffuser and the inlet fitting because longer components require morespace in which to install the water heater.

Yet another drawback of some existing water heaters is that the inletfittings lack integrated components for measuring the flow of waterthrough the fitting or shutting off the flow of water through thefitting.

The following disclosure describes example water inlet fittings, flowsensors, shut off valves, and diffusers that can address one or more ofthe foregoing limitations associated with water heaters and othersimilar devices.

SUMMARY

The present disclosure is directed to a flow sensor for a water heater.In one embodiment, an integrated flow sensor and diffuser for a waterheater include a flow sensor body with a diffuser attachment mechanismand a diffuser with a complementary attachment mechanism. An inlet ofthe flow sensor body includes an inlet attachment mechanism forattaching the flow sensor body to a water supply pipe. The diffuserattachment mechanism is located on an extended cylindrical flange at anoutlet of the flow sensor body. The complementary diffuser attachmentmechanism is configured to couple to the diffuser attachment mechanismof the extended cylindrical flange. The flow sensor body includes acavity for retaining a flow sensor. The integrated flow sensor anddiffuser can have a single set of threads on the outer surface of theextended cylindrical flange so that the integrated flow sensor anddiffuser can be attached to the water heater as a single assembly.

In another example embodiment, an integrated valve and flow sensorinclude a valve body, a rotatable ball disposed within the valve body, aflow sensor comprising a Hall effect sensor and a turbine disposedwithin the rotatable ball, a stem extending from the rotatable ball andcomprising a lead from the Hall effect sensor, and an actuator coupledto the stem for controlling the operation of the rotatable ball. Thelead from the Hall effect sensor can be coupled to a meter that measuresa flow of water through the integrated valve and flow sensor. An outletof the integrated valve and flow sensor can include an attachmentmechanism for mating with a complementary attachment mechanism of adiffuser.

In yet another example, a fitting for a water heater comprises a valve,an actuator coupled to the valve for opening and closing the valve, aflow sensor, and a heat trap. The flow sensor can comprise a turbine anda Hall effect sensor for measuring the flow of water through thefitting. The heat trap can prevent undesirable mixing or loss of heatedwater. The fitting can be coupled to either an inlet fitting or anoutlet fitting on a water heater.

These and other aspects and examples will be described in the followingdescription and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is a cross-sectional illustration of separate flow sensor anddiffuser components joined with a coupler as known in the prior art.

FIG. 2 is a cross-sectional illustration of an inlet fitting that is acombined flow sensor and diffuser assembly in accordance with an exampleembodiment of this disclosure.

FIG. 3 is a cross-sectional illustration of an inlet fitting that is acombined flow sensor, diffuser, and shut off valve assembly inaccordance with an example embodiment of this disclosure.

FIG. 4 is a perspective, partial cross-sectional illustration of aninlet fitting that is a combined flow sensor, diffuser, and shut offvalve assembly in accordance with an example embodiment of thisdisclosure.

FIG. 5 is a schematic illustration of an electric water heater with ashut off valve and flow sensor located at the inlet in accordance withan example embodiment of this disclosure.

FIGS. 6, 7, 8, and 9 are views from different angles of an inlet fittingthat is a combined flow sensor and shut off valve in accordance with anexample embodiment of this disclosure.

FIG. 10 is a partial cross section of the inlet fitting of FIGS. 6-9that is a combined flow sensor and shut off valve showing a heat trapinsert in accordance with an example embodiment of this disclosure.

DESCRIPTION OF EXAMPLE EMBODIMENTS

The example embodiments discussed herein are directed to systems,apparatuses, and methods for water heaters with optimized inletstructures, diffusers, flow sensors and shut off valves. The followingembodiments are non-limiting examples and those working in this fieldshould understand that various modifications can be applied to theexamples described herein without departing from the scope of thisdisclosure.

The components described herein can be made of one or more of a numberof suitable materials to allow the component or other associatedcomponents to meet certain standards and/or regulations. Examples ofsuch materials can include, but are not limited to, aluminum, stainlesssteel, copper, fiberglass, plastic, PVC, ceramic, and rubber.

Components described herein can be made from multiple pieces that can bemechanically coupled to each other using one or more of a number ofcoupling methods, including but not limited to epoxy, welding,soldering, fastening devices, compression fittings, mating threads, andslotted fittings. One or more pieces that are mechanically coupled toeach other can be coupled to each other in one or more of a number ofways, including but not limited to fixedly, hingedly, removeably,slidably, and threadably. An attachment or coupling feature can include,but is not limited to, a swage, a snap, a clamp, a portion of a hinge,an aperture, a recessed area, a protrusion, a slot, a spring clip, atab, a detent, a compression fitting, and mating threads.

Any component described in one or more figures herein can apply to anyother figures having the same label. In other words, the description forany component of a figure can be considered substantially the same asthe corresponding component described with respect to another figureunless otherwise noted. For any figure shown and described herein, oneor more of the components may be omitted, added, repeated, and/orsubstituted. Accordingly, embodiments shown in a particular figureshould not be considered limited to the specific arrangements ofcomponents shown in such figure.

Referring to FIG. 1, a cross-sectional illustration is shown of separateflow sensor 105 and diffuser 110 components joined with a coupler 115 asknown in the prior art. As described above in the Background Section,the separate flow sensor 105 and diffuser 110 components have drawbacksdue to their length and difficulty with installing the diffuser at theoptimal position for thermal efficiency. For example, the flow sensorand diffuser would typically be attached to a water heater fittinglocated on a top surface of a cylindrically shaped gas water heater sothat the diffuser extends down into the water heater tank. Installationrequires first attaching the diffuser 110 and coupler 115 to the waterheater with a first application of torque. When the diffuser is attachedto the water heater, it can be disposed at a particular position, suchas 2 o'clock for the diffuser outlet 112, that affects the circulationof the incoming water to optimize thermal efficiency. Second, the flowsensor 105 is attached to the coupler 115 with a second application oftorque. When attaching the flow sensor 105 to the coupler 115, thesecond application of torque can cause the diffuser to be rotated fromits optimal position.

In contrast, FIG. 2 is a cross-sectional illustration of an inletfitting that is a combined flow sensor and diffuser assembly 200 inaccordance with an example embodiment of this disclosure. In the exampleassembly of FIG. 2, the flow sensor body 205 includes an integralattachment mechanism 206 and an extending cylindrical flange 207 thatextends from the integral attachment mechanism 206 and outward away fromthe flow sensor body 205. The diffuser 210 attaches to the flow sensorbody 205 with a complementary attachment mechanism 214 that is integralto the diffuser so that the flow sensor and diffuser assembly 200 formsa single component and can be installed as a single component in a waterheater. As shown in FIG. 2, the attachment mechanism 206 can be aprotrusion and the complementary attachment mechanism 214 can be anotch. In alternate embodiments, the protrusion and notch can bereversed or can be any other readily know attachment mechanism such as aswage fitting.

The combined flow sensor and diffuser assembly 200 can have a single setof threads on the outer surface of the extended cylindrical flange 207so that the combined flow sensor and diffuser assembly 200 can beattached to the water heater as a single assembly. Because only onetightening procedure is required to attach the single flow sensor anddiffuser assembly 200, the installer is better able to ensure that thediffuser 210 is in the correct orientation to optimize the flow of thecold inlet water entering the water heater from the diffuser outlet 212.The combined flow sensor and diffuser assembly 200 also comprises aninlet 202 that is configured to couple to a water supply pipe.

The single flow sensor and diffuser assembly 200 is also an improvementover the prior art components shown in FIG. 1 because it has a shorterlength thereby allowing for installation in smaller spaces. Referring tothe non-limiting prior art example shown in FIG. 1, the joined flowsensor 105, diffuser 110, and coupler 115 have a combined length rangingfrom 10.25 to 10.50 inches. In contrast, the example combined flowsensor and diffuser assembly 200 of FIG. 2 has a length of 7.25 inchesthereby making it easier to install in small spaces. In other examples,the length of the combined flow sensor and diffuser assembly can varywithin a range of 5 to 8 inches. All dimensions shown in the figuresherein are in inches and should be considered non-limiting examples ofthe embodiments described herein.

FIGS. 3 and 4 illustrate a cross-sectional view and a perspective,partial cross-sectional view, respectively, of an inlet fitting 300 thatis a combined flow sensor, diffuser, and shut off valve assembly inaccordance with an example embodiment of this disclosure. Similar to theembodiment shown in FIG. 2, the embodiment shown in FIGS. 3 and 4includes a diffuser 310 with a complementary attachment mechanism 314,and the flow sensor body 305 with an extending cylindrical flange 307and an attachment mechanism 306. The attachment mechanism 306 andcomplementary attachment mechanism 314 can comprise a protrusion and anotch that lock together as shown in FIG. 3 or can comprising otherknown attachment mechanisms. The flow sensor body 305 shown in FIGS. 3and 4 can also include male threads 308 on the outer surface of theextending cylindrical flange 307 for mating with a female fitting on thewater tank.

The example embodiment shown in FIGS. 3 and 4 is similar to theembodiment shown in FIG. 2, except that it shows more details of theflow sensor and shows a shut off valve in the form of a ball valve thatis integrated with the flow sensor. While the diffuser 310 is shown inFIGS. 3 and 4, it should be understood that the combined flow sensor andshut off valve can be used without the diffuser 310 in certain exampleembodiments. The combined flow sensor and shut off valve shown in FIGS.3 and 4 provides advantages over the prior art in that the componentsare integrated into a single assembly thereby simplifying installationand reducing the space required when a shut off valve and flow sensorare separate components.

In the embodiment shown in FIGS. 3 and 4, the flow sensor comprises aturbine 318 a Hall effect sensor 320 and a sensor lead 322. The turbine318 is positioned inside the ball 324 of the ball valve and the Halleffect sensor 320 and the sensor lead 322 are located in the stem 326 ofthe ball valve. The flow sensor measures the flow of water through theinlet fitting 300 and, in conjunction with the Hall effect sensor 320,provides a signal via the sensor lead 322 to a meter that gathers dataindicating the flow of water into the water heater. In alternateembodiments, other types of flow sensors can be implemented in thevalve. A motor, not shown in FIGS. 3 and 4, can control the opening andclosing of the ball valve via the stem 326. Placing a shut off valve atthe entrance to the water heater provides advantages that includecontrolling the flow of water at the entrance to the water heater andbeing able to maintain a vacuum seal within the water heater.

Referring now to FIGS. 5-10, another example embodiment of an integratedinlet fitting, flow sensor and shut off valve is illustrated. Theembodiment illustrated in FIGS. 5-10 is in connection with an electricwater heater, however, the same concepts can also be applied to a gaswater heater. FIG. 5 shows a schematic illustration of an electric waterheater 500 with an inlet 502, an outlet 530, and two heating elements535. An inlet fitting 504 comprises an integrated shut off valve 524 andflow sensor 518 in accordance with an example embodiment of thisdisclosure. In contrast to the previously described fittings for gaswater heaters that included an optional diffuser, the electric waterheater 500 shown in FIG. 5 includes an optional dip tube 540 attached tothe inlet fitting 504.

FIGS. 6-10 show different views of an example inlet fitting 604comprising an integrated flow sensor and shut off valve in accordancewith the embodiment shown in FIG. 5. FIG. 6 is a top view of thefitting, FIG. 7 is a top perspective view of the fitting, FIG. 8 is aback view of the fitting, and FIG. 9 is a side view of the fitting. FIG.10 is a partial cross-sectional view of the fitting showing the flowsensor integrated into the shut off valve, but that omits, for purposesof clarity, the external components of the fitting shown in FIGS. 6-9.While the example shown in FIG. 610 is an inlet fitting, it should beunderstood that the same components can also be implemented in an outletfitting for a water heater.

FIGS. 6-10 show the inlet fitting 604 with an inlet 602, inlet threads603, an outlet 612, and outlet threads 608. The outlet threads 608permit the inlet fitting 604 to be attached to a fitting on the waterheater. The inlet threads 603 permit the inlet fitting 604 to beattached to a water supply pipe.

As shown in FIGS. 6-10, the integrated inlet fitting 604 combines a flowsensor and shut off valve into a single assembly that simplifiesinstallation. The integrated inlet fitting also requires less space thanif one were to install a separate flow sensor and a separate shut offvalve at a water heater inlet. FIGS. 6-9 show the shut off valve 624located inside the inlet fitting 604 and an electronic actuator 645connected to the inlet fitting via a valve stem 626. The electronicactuator 645 can be connected to a separate controller and/or powersource via lead 623 and the electronic actuator 645 controls the openingand closing of the shut off valve 624. The shut off valve 624 can be aball valve similar to the valve described in connection with FIGS. 3 and4, or another type of valve. Located within the shut off valve is aturbine 618 for measuring the flow of water through the inlet fitting604. The turbine 618 works with a Hall effect sensor 620, located on theouter surface of the inlet fitting 604, to provide signals to a meter,via lead 622, indicating the flow of water through the inlet fitting604. The integrated inlet fitting can also include a heat trap 650located inside the inlet fitting and downstream of the shut off valve624. The heat trap 650 is a valve that prevents the heated water withinthe water tank from flowing back through the inlet fitting and mixingwith the cold water from the water supply.

While example embodiments of integrated inlet fittings are discussedherein, the principles of the described embodiments can be applied to avariety of types of water heaters. Accordingly, many modifications ofthe embodiments set forth herein will come to mind to one skilled in theart having the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that water inlet structures, flow sensors, shut off valves,and diffusers are not to be limited to the specific embodimentsdisclosed and that modifications and other embodiments are intended tobe included within the scope of this application. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

What is claimed is:
 1. An inlet fitting for a water heater comprising:an inlet configured for fluid coupling to a water supply and comprisingthreads for threaded attachment to the water supply; an outletconfigured for fluid coupling to an inlet of a water heater andcomprising threads for threaded attachment to the inlet of the waterheater; a shut-off valve disposed between the inlet and the outlet ofthe fitting, the shut-off valve comprising a valve body, a valve stem,and a rotatable ball disposed with the valve body; and an electronicactuator for opening and closing the shut-off valve via controlling theoperation of the rotatable ball, the electronic actuator being coupledto the shut-off valve via the valve stem, wherein the inlet fitting iseffective to control a flow of water into the water heater and tomaintain a vacuum seal within the water heater.
 2. The inlet fitting ofclaim 1, wherein the electronic actuator is controlled by a controllercoupled to the electronic actuator via a lead.
 3. The inlet fitting ofclaim 1, wherein the inlet fitting is further configured for selective,operable fluid coupling to an outlet of a water heater.
 4. The inletfitting of claim 1, further comprising a heat trap downstream of theshut-off valve to prevent heated water from the water heater fromflowing through the inlet fitting and mixing with cold water from thewater supply.
 5. A fitting assembly for a water heater, comprising: theinlet fitting of claim 1; and a dip tube in communication with the inletfitting.
 6. A fitting assembly for a water heater, comprising: the inletfitting of claim 1, wherein the outlet further comprises: an extendedcylindrical flange comprising a diffuser attachment mechanism; and adiffuser with a complementary diffuser attachment mechanism, thecomplementary diffuser attachment mechanism configured to couple to thediffuser attachment mechanism of the extended cylindrical flange, thediffuser being configured to extend into a tank of the water heater. 7.A water heater, comprising: a tank comprising an inlet for receiving aflow of water from a water supply and an outlet for releasing heatedwater from the tank; a heating element configured to heat water in thetank; an inlet fitting coupled to the inlet of the tank, the inletfitting comprising: a fitting inlet configured for fluid coupling to awater supply and comprising threads for threaded attachment to the watersupply; a fitting outlet configured for fluid coupling to the inlet ofthe tank and comprising threads for threaded attachment to the inlet ofthe tank; a shut-off valve disposed between the fitting inlet and thefitting outlet, the shut-off valve comprising a valve body, a valvestem, and a rotatable ball disposed with the valve body; and anelectronic actuator for opening and closing the shut-off valve viacontrolling the operation of the rotatable ball, the electronic actuatorbeing coupled to the shut-off valve via the valve stem, wherein theinlet fitting is effective to control a flow of water into the tank andto maintain a vacuum seal within the tank.
 8. The water heater of claim7, wherein the electronic actuator is controlled by a controller coupledto the electronic actuator via a lead.
 9. The water heater of claim 7,wherein the inlet fitting is further configured for selective, operablefluid coupling to an outlet of the water heater.
 10. The water heater ofclaim 7, wherein the inlet fitting further comprises a heat trapdownstream of the shut-off valve to prevent heated water from the tankfrom flowing through the inlet fitting and mixing with cold water fromthe water supply.
 11. The water heater of claim 7, further comprising adip tube in communication with the inlet fitting.
 12. The water heaterof claim 7, wherein the fitting outlet further comprises: an extendedcylindrical flange comprising a diffuser attachment mechanism; and adiffuser with a complementary diffuser attachment mechanism, thecomplementary diffuser attachment mechanism configured to couple to thediffuser attachment mechanism of the extended cylindrical flange.